Classifications

• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H19/00—Coated paper; Coating material
  • D21H19/10—Coatings without pigments
  • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
  • D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31C—MAKING WOUND ARTICLES, e.g. WOUND TUBES, OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31C11/00—Machinery for winding combined with other machinery
  • B31C11/04—Machinery for winding combined with other machinery for applying impregnating by coating-substances during the winding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31C—MAKING WOUND ARTICLES, e.g. WOUND TUBES, OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31C3/00—Making tubes or pipes by feeding obliquely to the winding mandrel centre line
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
  • B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
  • B65H75/04—Kinds or types
  • B65H75/08—Kinds or types of circular or polygonal cross-section
  • B65H75/10—Kinds or types of circular or polygonal cross-section without flanges, e.g. cop tubes
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
  • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
  • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
  • D21H23/22—Addition to the formed paper
  • D21H23/52—Addition to the formed paper by contacting paper with a device carrying the material
  • D21H23/56—Rolls
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
  • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
  • D21H23/22—Addition to the formed paper
  • D21H23/52—Addition to the formed paper by contacting paper with a device carrying the material
  • D21H23/56—Rolls
  • D21H23/58—Details thereof, e.g. surface characteristics, peripheral speed
  • D21H23/62—Reverse roll coating, i.e. applicator roll surface moving in direction opposite to that of the paper
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2701/00—Handled material; Storage means
  • B65H2701/50—Storage means for webs, tapes, or filamentary material
  • B65H2701/51—Cores or reels characterised by the material
  • B65H2701/511—Cores or reels characterised by the material essentially made of sheet material
  • B65H2701/5112—Paper or plastic sheet material

Definitions

• the invention relates to coated paperboard cores suitable for use in winding yarns.
• elastomeric yarn such as spandex often involves winding of the yarn onto a core.
• adequate friction between the moving yarn and the surface of the core is required in order to start winding the yarn on the core.
• the surface of the paperboard core must be designed to resist the penetration of yarn oils such as lubricants and antistats in order to maintain the structural integrity of the paperboard core. Further, migration of the yarn oils from the yarn to the paperboard core may compromise the efficacy of the lubricants and antistats.
• Such films have been composed of polyester, cellophane, polyethylene, and polyvinylidene chloride (PVDC), such as SARANTM.
• PVDC polyvinylidene chloride
• the present disclosure in one aspect describes a paperboard core suitable for use in winding yarns.
• the paperboard core comprises one or more strips of paperboard wrapped about an axis and secured together to form an elongate structure, the elongate structure defining a winding surface.
• a coating which may comprise a PVDC polymer, covers the winding surface, wherein the coating is applied to the winding surface as a liquid and then cured.
• the coating may be applied by roll-coating, and may be substantially uninterrupted along the winding surface.
• the coating may comprise a plurality of individually applied layers, with each of the plurality of layers being cured before the next layer is applied atop it.
• the paperboard core may be repulpable without first removing the PVDC polymer.
• the elongate structure may comprise a tubular or conical shape.
• Embodiments of the invention further include a method of manufacturing a paperboard core suitable for use in winding yarns. The method comprises the step of winding one or more strips of paperboard about an axis to form an elongate structure defining a winding surface. The method further comprises the steps of applying a coating of a polyvinylidene chloride polymer to the paperboard and curing the coating.
• the step of applying the coating may comprise coating the winding surface, such as by roll-coating the polymer onto the winding surface.
• the method may include creating a substantially uninterrupted coating along the winding surface.
• the step of applying the coating may comprise applying a single layer or a plurality of layers of the polymer. When multiple layers are applied, the step of curing the coating may be repeated for each of the plurality of layers of the polymer.
• the coating may be applied to a radially outer surface of at least one of the one or more strips prior to the step of winding the one or more strips to form the elongate structure.
• the coating may be roll-coated onto the radially outer surface.
• one or more additional coats of the polymer may be applied to the winding surface after the step of winding the one or more strips which have been previously coated.
• FIG. 1 illustrates an embodiment of a partially disassembled paperboard core
• FIG. 2 illustrates embodiments of a method of manufacturing a paperboard core
• FIG. 3 illustrates results from moisture vapor transmission rates testing of paperboard samples
• FIG. 4 illustrates results from porosity testing of paperboard samples
• FIG. 5 illustrates basis weights for paperboard samples
• FIG. 6 illustrates a frictional force testing apparatus in a first position
• FIG. 7 illustrates a frictional force testing apparatus in a second position
• FIG. 8 illustrates frictional force testing results for a cellophane film-covered paperboard sample
• FIG. 9 illustrates additional frictional force testing results for the cellophane film- covered paperboard sample tested in FIG. 8;
• FIG. 10 illustrates frictional force testing results for a SARANTM film-covered paperboard sample
• FIG. 1 1 illustrates additional frictional force testing results for the SA ANTM film- covered paperboard sample tested in FIG. 10;
• FIG. 12 illustrates frictional force test results for a coated paperboard sample comprising one layer of polymer
• FIG. 13 illustrates frictional force test results for a coated paperboard sample comprising two layers of polymer
• FIG. 14 illustrates frictional force test results for a coated paperboard sample comprising three layers of polymer
• FIG. 15 illustrates frictional force test results for a coated paperboard sample comprising four layers of polymer.
• a film has been used in the past to prevent yarn oil from migrating into paperboard cores.
• a film refers to a thin sheet of solid material that is wrapped around the paperboard core.
• a coating refers to a substance that is applied in a liquid form, as opposed to a solid.
• Applicants have discovered that use of a pre-manufactured film for covering a paperboard core for use in winding elastomeric yarns is undesirable for a number of reasons.
• the film is typically wound in a helical fashion onto the paperboard core, and hence there may be gaps between each wrap of the film around the paperboard core.
• the film may be overlapped on each wrap, but this creates undesirable bumps along the surface of the paperboard core at the overlapping joints.
• either the film must be removed prior to recycling, or else costly sorting and filtering equipment must be incorporated into the recycling machinery.
• FIG. 1 illustrates an embodiment of a paperboard core 1 10 according to the present disclosure, the paperboard core 1 10 being illustrated in a partially deconstructed form.
• the paperboard core comprises one or more strips 1 12, 1 14 of paperboard wrapped about an axis 1 16 and secured together to form an elongate structure 1 18.
• the elongate structure 1 18 may comprise a tubular shape, as illustrated in FIG. 1. In alternate embodiments the elongate structure 1 18 may instead take the form of a conical shape, or other shapes depending on the specific application.
• the core 1 10 is illustrated as a spirally wound core in which the strips 1 12, 1 14 are helically wrapped, but cores in accordance with the invention can instead be convolutedly wrapped.
• the outermost portion of the paperboard core 1 10 defines a winding surface 120 on which yarns may be wound.
• the paperboard core 1 10 may require additional features to ensure oil resistance and sufficient friction with the yarn.
• a coating of a polymer material on the paperboard core 1 10 can provide superior oil resistance as compared to a film of the same type of material, as further described below.
• the material forming the coating which may comprise one or more layers, is preferably a PVDC polymer.
• the coating may be made of a low density polyethylene (LDPE) polymer.
• the coating may be applied as a liquid onto the paperboard core 1 10 such as by roll- coating the polymer onto the winding surface 120, and then dried or otherwise cured to make the coating substantially uninterrupted along the winding surface. Multiple layers of the coating may be sequentially applied and cured individually. It may be unexpected that a coating could provide superior oil resistance as compared to a film, particularly because the porous surface of the strips 1 12, 1 14 of paperboard might be expected to hinder the formation of a uniform layer of the polymer material. One skilled in the art may instead expect that a film would act as a better barrier than a coating, because of the more-uniform nature of the film.
• LDPE low density polyethylene
• Embodiments of the present disclosure include methods of manufacturing a paperboard core 1 10 suitable for use in winding yarns, as described above and illustrated in FIG. 1.
• the method may comprise a step 210 of winding one or more strips of paperboard about an axis to form an elongate structure defining a winding surface.
• the method further comprises the step 212 of applying a coating of PVDC or other polymer such as LDPE to the paperboard.
• the method further comprises the step 214 of curing the coating, such as by drying.
• the step 212 of applying the coating may comprise coating the winding surface of the core after the paperboard is wound. Additionally, the step of coating the winding surface may further comprise creating a substantially uninterrupted coating along the winding surface.
• a paperboard core with a coating may avoid overlapping joints or gaps associated with use of a film.
• the step of coating the winding surface may comprise roll-coating the polymer onto the winding surface.
• the step of roll-coating the polymer may comprise rotating the paperboard core against a rotating cylinder that is partially immersed in the polymer.
• the step 212 of applying a coating of the polymer may take a number of different forms. For example, additional embodiments may spray-coat the polymer onto the winding surface, or apply the polymer onto the winding surface using a wick, brush, or the like.
• the step 212 of applying the coating may comprise coating the radially outer surface of at least one of the one or more strips prior to the step 210 of winding the one or more strips.
• the step 212 of applying the coating may comprise roll-coating the polymer onto the radially outer surface of the one or more strips.
• Other methods, such as spray-coating or wick-coating, as discussed above, may alternatively be used to coat the strips of the paperboard.
• the step of coating the radially outer surface may further comprise the step of coating the winding surface after the step 210 of winding the one or more strips.
• the method combines both coating the strips prior to winding and coating the winding the surface after winding. The combination of these two steps may provide additional oil resistance.
• the polymer coating may be applied before, after, or both before and after the strips 1 12, 1 14 of paperboard are wound about the axis 1 16 to form the elongate structure 1 18.
• the polymer coating may not resist oil as well as when the winding surface 120 is coated after the strips of paperboard are wound about the axis to form the elongate structure. This is because seams 122 between the one or more strips 1 12, 1 14 of paperboard may provide pathways through which oil may migrate.
• the step 212 of applying the coating may comprise applying a single layer of the polymer.
• the step 212 of applying the coating may comprise applying a plurality of layers of the polymer.
• the step 214 of curing the coating may be repeated for each of the plurality of layers of the polymer, such that each layer is cured before the next layer is applied to it.
• the curing of each layer individually may allow the plurality of layers to combine to form a thicker coating, for example when the liquid polymer is relatively thin (i.e., of low viscosity) and cannot otherwise be thickened.
• the number of layers of the coating affects the oil resistance and frictional properties of the paperboard core.
• Tests were conducted using coated paperboard and film-covered paperboard samples.
• One film used in the tests was a SARANTM film, which consists of a PVDC polymer.
• the coated paperboard comprised coatings of a PVDC polymer. Samples having from one to four layers of PVDC were tested. Additionally, the tests were conducted on uncoated paperboard, which served as a baseline.
• MVTR moisture vapor transmission rate
• the MVTR testing showed that for the uncoated paperboard, the MVTR was very high, and hence this sample failed the MVTR test. This was expected because paperboard is known to have poor oil resistance qualities.
• the MVTR data for the remainder of the samples is displayed in FIG. 3, in terms of grams per 100 square inches per day. As illustrated, the sample comprising a single-layer coating resulted in a greater MVTR than the SARANTM film sample. Specifically, the single layer coating sample was found to have an MVTR of 2.82 gm./100 in. 2 /day, whereas the SARANTM film sample had an MVTR of 0.54 gm./100 in. 2 /day.
• coated samples comprising two to four layers of PVDC polymer provided lower moisture vapor transmission rates than that of the SARANTM film sample.
• the coated samples with two to four layers of polymer yielded moisture vapor transmission rates between 0.09 gm./100 in. 2 /day and 0.02 gm./100 in. 2 /day.
• the coated samples comprising two to four layers were found to be superior to the SARANTM film-covered sample in this test.
• coatings comprising two to four layers provided significantly better moisture transmission rates, less than a fifth that of the SARANTM film-covered sample.
• Porosity is a measure of the void spaces in a material. Porosity was tested by determining the time that elapses for one hundred cubic centimeters of air to pass through each sample. The test was conducted using a Densometer #45405
• the porosity data for the samples is illustrated in FIG. 4. Porosity is displayed in seconds, with longer times corresponding to lower porosity, and hence longer times are indicative of better oil resistance. As illustrated, the test volume of air was able to travel through the uncoated paperboard core in only 22 seconds. The time was 519 seconds for the coated sample comprising one layer of PVDC. For the SA ANTM film-covered sample, the time was 1 1 ,274 seconds. The coated samples comprising two to four layers of PVDC achieved times between 9,602 seconds and 15,837 seconds, which are of similar magnitude to that provided by the SARANTM film-covered sample. While there is some variability among the data for the coated samples, overall the data show that the coated samples comprising two to four layers of polymer are of similar porosity to that of the SARANTM film-covered sample.
• each of the coatings having one to three layers uses less PVDC on a mass per unit area than the SARANTM film basis, with the three layer coating at 4.76 lbs./1000 ft. 2 being nearly equal to that of the SARANTM film.
• each of the coated samples comprising one to three layers of PVDC may be fairly compared to the SARANTM film-covered sample without concern that the positive results are merely due to use of a greater mass of PVDC.
• the coating comprising four layers the four coatings have a greater basis weight than the SARANTM film.
• the weight of the adhesive is factored in, which is not required in the coated samples, less total material on a mass per unit area basis is applied to the paperboard for even the coated sample comprising four layers.
• the tension tester 610 comprises a jig 612 that is round to simulate the shape of a paperboard tube. A paperboard sample 614 is secured on the round jig 612 and a length of spandex yarn 616 is wrapped partially around the sample on the jig. The upper end 618 of the spandex yarn 616 is attached to a moveable head 620. As illustrated in FIG. 6,
• the moveable head 620 is translated in a vertical direction 622 so as to pull the spandex yarn 616 across the sample 614 on the jig 612.
• the force required to pull the spandex yarn 616 over the sample 614 was recorded for each of the samples.
• FIGS. 12-15 illustrate the results of the friction tests.
• the results of testing a coated sample comprising a single layer of PVDC are illustrated in FIG. 12 and the test results for a coating comprising two layers are illustrated in FIG. 13.
• the friction behavior of these coated samples creates an upward sloping curve similar to that created by the film-covered samples, except the magnitude of the force is less, with the maximum recorded force for these two samples being less than 1.5 grams-force. It is unclear why the coating comprising two layers of polymer, as illustrated in FIG. 13, resulted in less maximum force than the coating comprising one layer of polymer, as illustrated in FIG. 12.
• the coated sample comprising three layers of the polymer yielded a maximum recorded force exceeding 3 grams-force, which is within the range of the maximum recorded forces from the film-covered samples.
• the three layer coated sample also produced a generally upward sloping curve. Accordingly, the three layer coated sample demonstrated frictional characteristics similar to that of the film-covered samples.
• coated sample comprising four layers was tested. As illustrated in FIG. 15, this sample additionally produced a generally upward sloping frictional curve. However, the maximum force produced as the spandex yarn was dragged across the four layer coated sample was over 5 grams-force, which exceeds the maximum recorded force produced by the film-covered samples. Accordingly, depending on the number of layers of coating applied, coated paperboard cores may produce frictional force equaling or exceeding the frictional force produced by film-covered paperboard cores.
• the desired frictional and moisture barrier properties of the paperboard core at least in part by selecting the number of layers of the polymer which are applied.
• the frictional and moisture barrier properties corresponding to each number of layers of polymer may be determined empirically as described above, or by other methods. Other variables, such as the thickness of each layer, may also affect the moisture barrier and frictional properties, and hence may also be adjusted in order to obtain the desired properties of the paperboard core.
• coated paperboard cores may create the necessary friction required for yarn transfers, and may also unexpectedly provide better moisture barrier properties as compared to a film depending on the number of layers of polymer comprising the coating.
• coated paperboard cores may have additional benefits in that use of a coating instead of a film may allow the core to be recycled using conventional processes without first removing the PVDC polymer.
• it may be necessary to either remove the film prior to recycling or use costly sorting and filtering equipment in the recycling process.
• coated paperboard cores may provide viable substitutes for film-covered paperboard cores while providing additional benefits not produced by film-covered paperboard cores.

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Citations (4)

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• 2009
  • 2009-09-09 US US12/555,984 patent/US20110057069A1/en not_active Abandoned
• 2010
  • 2010-09-08 MX MX2012002880A patent/MX2012002880A/es not_active Application Discontinuation
  • 2010-09-08 CN CN2010800480757A patent/CN102597370A/zh active Pending
  • 2010-09-08 EP EP10755035A patent/EP2475820A1/en not_active Withdrawn
  • 2010-09-08 WO PCT/US2010/048038 patent/WO2011031698A1/en active Application Filing
  • 2010-09-08 SG SG2012016804A patent/SG179073A1/en unknown
  • 2010-09-09 TW TW099130535A patent/TW201116658A/zh unknown

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